Every manufacturing process has its own unique set of challenges. Thanks to increased complexity and a lack of standardization, the parts marking process is no exception.
Let’s take a look at 10 factors that will help you narrow down the options when choosing a direct part marking method for your project:
Important factors in the industrial parts marking process: who, what, where and how much?
Every company’s needs are unique. As there is no “miracle” parts marking process, it’s imperative to be aware of these 10 factors:
- Marking content
- Marking location
- Part size
- Marking size
- Part geometry
- Product range
- Production volume
- Operating environment
- Product form and function
- Budget
Marking content
The first question to ask is what specifically will be marked on the part:
- Text characters
- Logos
- Bar codes or Datamatrix
Most marking devices are able to mark text characters as a standard function. However, more complex elements, such as logos, barcodes and 2D codes, may require a software upgrade.
Another factor to consider is the size and density of the marking.
Ask yourself these questions:
- How many lines of text?
- What is the total marking area required for all elements, i.e. text, logos and barcodes?
- Will all elements fit within the mechanical limits of the marking device itself?
Marking location
Once you’ve answered the “what” question, the next question is where the marking will be made on the part. Is the space available for marking easily accessible, or are there unique features of the part that limit or obstruct access to the marking surface? Can the marking tool make physical contact with the part surface, or do you need a non-contact marking method?
Part size
Part size determines how (and where) the marking process takes place:
Small parts that are light enough to be transported and handled by hand can be presented to the marking station at a fixed location (such as an operator’s assembly cell).
In the case of large or heavy parts, it’s not always practical to transport and load the part to a fixed location for marking. In this case, a portable solution is recommended: the marking device can be brought to the part, which is in a fixed location such as a storage rack or pallet.
Marking size
The size of the part often determines the size of the marking itself.
Most parts have a sufficiently large surface area to apply permanent markings that are visible to the naked eye. For very small parts, or for parts with a limited available marking surface, a mechanical marking technique such as dot peen may not be feasible. Laser marking, on the other hand, is capable of producing highly precise micro-marks.
Part geometry
Will the marking be located on a flat, curved or complex surface?
Any marking device must be able to mark on a flat surface in a simple XY plane. However, more advanced and complex marking (such as 360° marking around the circumference of a cylindrical component) often requires the addition of a rotary axis.
Even more challenging, complex surfaces require a marking device capable of controlling three axes of movement, X,Y and Z, to produce a quality mark that follows the contour of the part.
Product range
Will the marking machine be dedicated to a specific product, or will it be used as a general-purpose tool for marking a wide variety of parts?
A dedicated marking system can be adapted to the particular needs of a given product application with minimum operator intervention.
A low-volume production environment with a wide variety of products requires a flexible marking system. A flexible marking system eliminates the need for dedicated tooling and minimizes operator set-up time between production cycles of different parts.
Production volume
The volume of parts to be marked in a given space or time will determine the work cycle of the marking machine. Production rates can be defined in terms of :
- Parts per hour
- Parts per shift
- Parts per day
For low-cycle product applications of less than 100 parts/day, a relatively inexpensive entry-level marking machine may be sufficient to meet production requirements. Production batches of several hundred or thousands of parts per day require a more robust industrial marking machine, capable of withstanding a higher work cycle.
The level of process automation required to keep pace with the desired production rate will also depend on the production volume. For low-volume production, an operator can manually feed parts to a marking station.
When throughput reaches hundreds of parts per day, semi-automation, such as a pneumatic shuttle or two-position dial plate, can help the machine operator keep pace with production. For high-volume production of several thousand parts a day, a fully automated marking system requiring minimal operator intervention is ideal.
Product shape and function
What is the planned use of the part to be marked?
The marking process must not alter the shape, fit or function of the part itself, as this could become structurally compromised or unusable.
Controlled surfaces require a marking method that does not displace or remove material from the part surface, such as laser marking. On the other hand, product surfaces that are exposed to extreme pressure differential (such as pipe and valve fittings) require a low-stress marking method, such as micro-percussion, which does not introduce thermal shock or stress fracture into the material.
Working environment
Operating conditions in the production environment are an important consideration when choosing the right marking machine for the job. Ask yourself the following questions
- Will the marking equipment be used indoors or outdoors, or both?
- Is the operating environment relatively clean, or will the marking machine be exposed to dust, oil splashes or liquids such as machining fluids?
- Is the production area air-conditioned, or subject to seasonal temperature extremes?
- What is the operator’s skill level?
Budget
Although not a direct process consideration, budgetary constraints will have an impact on the part marking technology to be purchased. In the end, “the right tool for the job” often becomes “the best tool for the available budget”.
A word of caution: many manufacturers fall into the trap of false economy by focusing solely on the initial outlay for marking equipment, only to suffer higher operating costs due to production bottlenecks and machine downtime because a part isn’t up to the job. But why compromise?
Look for equipment manufacturers who offer equipment financing programs. Financing programs enable manufacturers to acquire the best marking technology for the job while retaining the flexibility to pay for it over time from the operating budget, rather than going through a traditional capital expenditure approval process.
Let our experts help you
Talk to one of our consultants about your marking project! We’ll be glad to offer you the best solutions to meet your needs.
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